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Hello everyone. Like most, I'm new here but not to Honda's although not a transmission expert..yet... maybe I will be after this one. I would greatly appreciate some input from some real transmission experts. I rebuilt my K4F D-series transmission last week. It was my first time rebuilding a transmission. I followed a write up I found on Honda tech. Everything shifted and spun good out of the car. I put it back in the car an started it up and it makes this really loud sound like a rod knocking. The engine runs great so I don't think it would be an actual rod knock. I have replaced clutches before so that process is not new to me. The clutch was replaced 2 years ago and worked fine before the rebuild. Trans shifts into any gear fine while this is going on. Sounds like its coming from the bell housing area. I removed the clutch dust cover in case it was rubbing something and it didn't fix it. I also removed the starter with the engine running to see if it was sticking but that didn't do it either. It sounds exactly like this video I found on another thread on Honda tech. This guys issue ended up being a new pressure plate being the wrong one hitting the bell housing. I can't see that being an issue because I didn't touch the clutch or pressure plate. Here's the video since I can't post links yet, if you search 98 Honda Civic Transmission Noise Tapping on YouTube it comes up.
. Also it quiets down a bit with clutch in. Maybe I broke a PP spring when installing.
. I am going to remove the trans tonight to look for anything obvious. Any possible culprits to look for would be great. Thank you.
 

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Hey thank for the reply!! I replaced bearings, Synchro's and seals. Ok update. Today I realized I didn't grease the throw out bearing shaft of shift fork. So I tried to grease them the best I could without removing the trans. I used high temp grease and a brush. It quieted it up a lot but not all together. Then I got the idea to push on the shift fork to engage the TB on the pressure plate, the noise got quieter. Then I adjusted all the freeplay out of the clutch pedal and now when clutch is in there is no noise but still noise when it's out. I decided to take it for a ride and see if maybe it would seat something. Good new is the transmission shifts beautifully. One of the best shifting transmissions I have ever driven. When I got back the noise was quieter. I kept it running and got a crow bar and forced the clutch form against the pressure plate. Noise completely stopped at idle. I depressed the clutch a few times and no noise. I then decided to loosen the clutch adjustment a little bit. Bang the noise is back. The TB didn't make noise before rebuild and is only 2 years old. I took video but when I import them they are like 2 seconds long, useless. Any clue?
 

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Remove the trans, replace the throwout bearing, and grease the bearing and fork.

Not lubing the fork will cause bad things to happen, such as the fork breaking.
 

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Thanks again. Yes I think I will replace the TO bearing as you suggested. I will update with the fix incase someone else has this issue. Nothing more aggravating than following a thread pages and the OP not post the solution.
 

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Ok found the issue. I'm dumb and put a washer under that hex plug. I could of sworn there was one in there. I'm sure everything will operate smoothly now. Knew it would be something stupid.
 

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